Concrete composite non-meshed wall finishing system over key lock grid substrated

ABSTRACT

A novel concrete composite non-meshed wall finishing system over key lock grid substrate ( 9 ) comprising of at least one foam-type building panel ( 10 ), and at least on one side of said panel a multi-number of a vertical keyed locking groove ( 11 ), a multi-number of a horizontal keyed locking groove ( 12 ) placed approximately at a 90 degree angle to said vertical keyed locking groove ( 11 ) forming a keyed locking grid substrate ( 13 ), which allows a fiber-reinforced acrylic-modified cementaceous base coat ( 14 ) to fill in and cover said keyed locking grid substrate ( 13 ) thereby giving sufficient strength to said fiber-reinforced acrylic-modified cementaceous base coat ( 14 ) to support a synthetic or non-synthetic colored finish ( 15 ) as a final exterior finish.

BACKGROUND

[0001] 1. Field of the Invention

[0002] This invention relates in general to a semi-synthetic stucco system and substrate, generally referred to as an Exterior Insulation and Finishing system or EIFS, in particular for a concrete composite non-meshed wall finishing system over key lock grid substrate which allows various heights and lengths of panels having a key grooved type substrate which holds the base coat on the wall, helps gage a desired thickness and traps fiber type reinforcing in grooves allowing the applicator the ability to apply a thicker coat of base without the need to level out the wall after the coat of base is applied. My invention eliminates the need for mesh and/or wire.

[0003] 2. Description of Prior Art

[0004] Prior art have higher cost in labor and materials and have a traditional one and three coat stucco systems. All of the prior art systems have some kind of mesh or wire reinforcing to improve impact properties, reduce cracking and aid in the application of the base coat. The prior art panels are more complicated in assembling or applying the base coating because of the mesh or wire reinforcing system.

[0005] Another type mat-faced gypsum board and method of manufacturing same. The mat-faced gypsum board of the general type having a gypsum-based core formed a gypsum slurry compressed through an extrusion ratio of at least about 3:1 having the fibrous mat-facing on at least one side of the board and consists essentially of inorganic fibers having a diameter of less than about 15 microns. The difficulties with the prior art is it requires a more intense labor and material which increases the cost of the panel, therefore, less affordable by the end user.

[0006] Another type high strength fabric reinforced walls a method for reinforcing the face or faces of walls so as to prevent or reduce the likelihood of failure when such walls are subjected to loads that are encountered during earthquakes. The prior art includes the step of applying a resin-impregnated fabric layer over a portion of an exposed face of a wall to be reinforced. The prior art includes the further step of anchoring the resin-impregnated fabric layer to a structural member of the wall using fabric fasteners, adhesives or a combination of these items. The disadvantage of this prior art is that it's more elaborate, more costly, more intense labor to assembly and is limited because of its cost to manufacture and its greater number of parts to build a wall and one of the greatest draw backs is the use of a reinforcing fabric. My invention makes this method of reinforcing obsolete by doing away with the need for a reinforcing fabric.

[0007] Another type floor structure for indoor artificial skiing ground which is made up of a concrete base plate constructed on foundations, having a first waterproof covering disposed on the base plate and a heat insulation layer located on the first waterproof covering and a second waterproof covering disposed on the heat insulation layer, and a concrete pressing plate located on the second waterproof covering and a plurality of drainage grooves formed on top of the pressing plate. This prior art relates to floor structures. The disadvantage of this prior art is its elaborate construction, if it is applied to a wall structure because of its inabililty to stand vertical for a wall panel. Therefore, it is designed specifically for a floor application not for a wall application.

[0008] Another type protective coating system having a suitable mesh screen of plastic, metal or the equivalent on the surface to be protected, having a thin layer of coating composition such as a latex cement which is poured over the mesh and allowed to set. Thereby, the mesh is bonded by means of the coating composition to the surface. The mesh screen protrudes to the upper surface of the coating composition giving aid to both layers, thereby forming resistance to separating caused from expansion or contraction of said surfaces. This prior art using mesh screen is more elaborate than my invention because by invention uses no mesh screen, thereby making my invention less expensive, less cost to manufacture and less labor in assembly.

[0009] Another type prefabricated wall panel for a structural and insulating panel for walls of buildings. The panels include meshes forming lateral surfaces, ziz-zag wires joining the meshes together and webs and backings acting to contain the flow of liquid insulation as it is sprayed onto the walls. The disadvantage of this prior art is that it uses meshes, zig-zag wires, webs and backings making it more elaborate, more expensive and more intense labor cost. My invention uses no mesh or wire, thereby having a more general commercial application over the prior art design.

[0010] Another type is a composite module with reinforced shell, having a rigid foam core encapsulated in a shell of reinforced cementitious material. The shell is reinforced with at least two types of materials, one being a fiber reinforced material distributed in an interconnected random matrix substantially throughout the shell and a second being a scrim reinforcing material adjacent to at least one surface of the shell and/or the rigid foam core. The disadvantage of the prior art is the dense layer of fiber reinforcement, cement with fiber matrix. My invention is more simplistic in design causing the cost of manufacture less expensive and designed with great strength.

OBJECTS AND ADVANTAGES

[0011] Accordingly, besides the objects and advantages described above, several objects and advantages of the present invention are:

[0012] (a) to provide a reduction in the overall cost of labor.

[0013] (b) to provide a reduction in the cost of materials used.

[0014] (c) to provide for the substrate in being key grooved to help hold the base coat on the wall without using mesh or wire.

[0015] (d) it eliminates the need for mesh and/or wire.

[0016] (e) to provide the applicator the ability to apply a thicker coat of base without the need to level out the wall after the coat material is applied.

[0017] (f) allows the chopped fiber reinforcing in a cement type product that can be mixed with other modifiers such as acrylic to improve strength and flexibility.

[0018] (g) to provide for improved impact properties.

[0019] (h) to provide for reduced cracking of panels.

[0020] (i) to provide a substrate having a foam type product with grooving grid on one or two sides of panel.

[0021] (j) to provide for a simplistic design with great strength.

[0022] (k) to provide a universal concrete composite non-meshed wall finishing system.

[0023] (l) to provide a replacement of the traditional exterior insulation and finishing system with a less elaborate design.

[0024] It is an object of the present invention to provide an improved concrete composite non-meshed wall finishing system over key lock grid.

[0025] Other objects and features are readily apparent from the following description of certain preferred embodiments thereof taken in conjunction with the accompanying drawings although variations and modifications may be affected without departing from the sphere and the scope of the normal concepts of the disclosed invention. You will find further objects and advantages of this invention from a consideration of the ensuing descriptions and accompanying drawings.

DRAWING FIGURES

[0026]FIG. 1 Shows a top view of the panel having vertical and horizontal grooves, taken along line 1-1 FIG. 2.

[0027]FIG. 2 Shows an exploded front view of the panel having vertical and horizontal grooves, taken along line 2-2 FIG. 4.

[0028]FIG. 3 Shows a front view of the concrete composite non-meshed wall finishing system over key lock grid substrate.

[0029]FIG. 4 Shows a top view of the concrete composite non-meshed wall finishing system over key lock grid substrate, taken along line 4-4 FIG. 3.

DRAWING REFERENCE NUMERALS

[0030]9 concrete composite non-meshed wall finishing over key lock grid substrate

[0031]10 foam-type building panel

[0032]11 vertical keyed locking groove

[0033]12 horizontal keyed locking groove

[0034]13 keyed locking grid substrate

[0035]14 fiber-reinforced acrylic-modified cementaceous base coat

[0036]15 synthetic or non-synthetic colored finish

DESCRIPTION OF INVENTION

[0037] The concrete composite non-meshed wall finishing system over key grid substrate 9 shown in FIG. 1, FIG. 2, FIG. 3 and FIG. 4, comprises of at least one foam-type building panel 10 having sufficient thickness, width and thickness, a multi-number of a vertical panel keyed locking groove 11 having sufficient depth, width and length, can be applied to at least one side of said panel, a multi-number of a horizontal keyed locking groove 12 placed approximately at a 90 degree angle to said vertical keyed locking groove 1 making up a keyed locking grid substrate 13, FIG. 3, said vertical and horizontal grooves of the keyed locking grid substrate 13 which allows a fiber-reinforced acrylic-modified cementaceous base coat 14 having sufficient thickness to fill in and cover said vertical and horizontal keyed grooves giving sufficient strength for the keyed locking grid substrate 13. Once the fiber-reinforced acrylic-modified cementaceous base coat is sufficiently dry, then a synthetic or non-synthetic colored finish 15, FIG. 3 is applied as the exterior finish. The concrete composite non-meshed wall finishing system over key lock grid substrate 9 can be made from concrete, stone, brick, foam, plastic, wood, iron, steel, aluminum, or any other type metal, polyurethane type composite with fiberglass, high density expanded polystyrene, plastic or any combination of these materials.

CONCLUSION AND SCOPE OF INVENTION

[0038] Accordingly, the reader will see that the concrete composite non-meshed wall finishing system over key lock grid substrate of this invention has the ability to be manufactured and installed in a fraction of the time compared to masonry or solid concrete panels with less material costs. Furthermore, the concrete composite non-meshed wall finishing system over key lock grid substrate has additional advantages in that:

[0039] it provides a reduction in the overall cost of labor.

[0040] it provides a less expensive material cost.

[0041] it provides using less materials in manufacturing.

[0042] it eliminates the use of fabric mesh and/or wire mesh.

[0043] it improves the impact properties

[0044] it reduces material cracking

[0045] it provides for a chopped fiber-reinforcing cement type product that can be mixed with other modifiers such as acrylic to improve strength and flexibility.

[0046] it provides for the substrate to be preferably a foam type product with grooving or some form for water drainage on one side and key type grooving grid on the opposite side or both sides may be grooved alike.

[0047] it provides that the substrate may be glued, wind-locked, or stapled to sheeting or other substrates.

[0048] it allows the applicator the ability to apply a thicker coat of base without the need to level out the wall panel after the base is applied.

[0049] it allows the vertical and horizontal grooves to trap the fiber type reinforcing base coat in the grooves.

[0050] it provides a unique construction for a concrete composite non-meshed wall finishing system over key lock grid substrate.

[0051] Although the description above contains many specifications, these should not be construed as limiting the scope of the invention but merely providing illustrations of some of the presently preferred embodiments of this invention. For example, the foam-type building panel or the shape of the vertical and horizontal grooves or the keyed locking grid substrate can have other shapes, such as square, oval, trapezoidal, triangular, curved, etc. The exterior surface of the panel can be of different material combinations.

[0052] Thus, the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given. 

I claim as my invention:
 1. A concrete composite non-meshed wall finishing system over key lock grid substrate which comprises at least one foam-type building panel having sufficient thickness, width and length, a multi-number of a vertical keyed locking groove having sufficient depth, width and length, being applied to at least one side of said foam-type building panel, a multi-number of a horizontal keyed locking groove having sufficient depth, width and length, being applied to at least one side of said foam-type building panel at a 90 degree angle to said vertical keyed locking groove forming a keyed locking grid substrate. Said keyed locking grid substrate allows a fiber-reinforced acrylic-modified cementaceous base coat having sufficient thickness and strength to fill-in and cover said vertical keyed locking groove and said horizontal keyed locking groove giving sufficient strength for the said keyed locking grid substrate to support said fiber-reinforced acrylic-modified cementaceous base coat, and a synthetic or non-synthetic colored finish having sufficient thickness.
 2. The concrete composite non-meshed wall finishing system over key lock grid substrate according to claim 1 wherein said keyed locking grid substrate having sufficient area between said vertical keyed locking groove and said horizontal keyed locking groove allowing sufficient strength for support of said fiber-reinforced acrylic-modified cementaceous base coat.
 3. The concrete composite non-meshed wall finishing system over key lock grid substrate according to claim 1 wherein said synthetic or non-synthetic colored finish to be applied to said fiber-reinforced acrylic-modified cementaceous base coat as a final exterior finish. 